Operating PrincipleFulton FB-S three-pass/wet-back/horizontal steam boilerThe standard design for FB-S is a three-pass, wet-back with corrugated furnace. In the first pass, the flame and high temperature flue gas flow from the front to the back of the furnace; Through the second pass tubes, high temperature flue gas flow from the return chamber to the front chamber; In the third pass, the flue gas passes through the third pace tubes to the back of the boiler stack and then vents out.
Corrugated furnace and wet back designFB-9 boiler’s large diameter corrugated furnace provides a generous heating surface for increased heat transfer and reduced heat flux. The corrugation also reinforces the strength of the combustion chamber, and increases the longevity of the pressure vessel due to a substantial reduction in thermal and mechanical fatigue caused by cyclic expansion and contraction. The wet-back design eliminates heavy refractory on rear door while increasing efficiency and reducing radiant loss.
Large Water ContentFB-S boiler’s large water content and steam chamber ensure low sensitivity to load change, and stability of steam pressure 6 steam quality. Combustion chamber located well below water level with generous clearance from bottom of boiler allowing proper simulation. Adequate space between combustion chamber and water level ensures high quality steam by minimizing carry over.
Well-insulated Front Gas ChamberGas chamber Is not a part of the pressure vessel, but plays an important role in boiler operation. Fulton utilizes the “air-insulation” design to reduce heat loss in the FB-S series boiler. The large furnace surface area also reduced furnace exit temperature via enhanced radiation and convection.
Operating PrincipleFuel is injected from the burner into the combustion chamber and is ignited and burned. The combustion chamber constitutes the first past. Then a combustion turnaround section directs the flue gas to the second pass tubes. The turnaround section is water surrounded and thus called the “wet-back”. In the third pass, gases travel from the second pass tubes to the third pass tubes and finally exit out the stack.
4 Pass Design For Optimum EfficiencyFulton FB-C boilers’ four pass design adds additional heating surface to the traditional three pass, which further enhances the heat exchange between the flue gas and boiler water. This four pass design plus the fully matched IC burner achieve the optimum efficiency for FB-C/FB-D boilers.
High Efficiency full modulation burner
Advanced burner control system for safety and high efficiencyFulton FB-C series burner control system has strong control, test and diagnose functions. The burner programmer monitors the burner ignition, operation and flame. It also works with water relay and pressure control to ensure the boiler safety. FB-C boiler has flame failure; oil pump, water pump, and air motor overload protection, low water cut-off, and high pressure cut-off, high temperature cut off for hot water boiler and high-low gas pressure interlocks.
Wet-back and corrugated furnace designBoth 3 pass and 4 pass FB-C boilers all have the wet-back and corrugated furnace design feature. The corrugation of the furnace provides additional heat transfer surface. It also reinforces the strength of the combustion chamber and increases the longevity of the pressure vessel. Corrugation greatly reduces the thermal and mechanical fatigue caused by cyclic expansion and contraction. Wet-back design eliminates the need for refractory lining, baffles, and gaskets and provides additional heating surface.
Operating Principle and Structural FeaturesFulton RB boiler is a wet-back horizontol boiler. Fuel is injected from the burner into the combustion chamber and is ignited and burned. The high temperature flue gas reverses back after reaching furnace end plate. Heat from the flue gas is passed to boiler water through convection and conduction. Then the flue gas flows into fire tubes through front chamber, transferring residual heat to boiler water. Finally the cooled low temperature flue gas vents into stack via rear chamber.
Large Furnace Volume, Large Furnace Surface Area, Better Combustion, Higher EfficiencyWith large furnace volume and furnace heating surface, RB boiler has low combustion intensity, typically less than 1000 kw/m2. The large furnace and large furnace surface area also reduce furnace exit temperature via enhanced radiation and convection, front gas chamber condition is much better than regular reverse fire boiler, thus ensures front gas chamber durability.
Large Number Of Fire Tubes And Large Tube Total Cross-Sectional AreaWith large tube total cross-sectional area, the resistance to gas flow is reduced, so the burner can be equipped with smaller motor to reduce power consumption.
Large Water Content, Low Sensitivity To Load ChangeLarge water content and steam chamber ensures low sensitivity to load change, and stability of steam pressure & steam quality.
Low NOx EmissionFulton RB boiler adopts large furnace volume, reduces combustion intensity noticeably. Emission of NOx is limited to a quite low level, which comply with the latest European and North American’s environmental requirements.
Fulton manufactures a complete line of electric steam boiler from 12 kW to 2000 kW (1.2 to 200BHP) up to 300 PSI for heating and process applications.Fulton’s vertical design is a full packaged boiler built to ASME specifications and applicable standards and codes. They are very efficient because the heating elements are totally immersed in water and the pressure vessel is fully insulated. Radiation losses are minimal. With a carefully calculated heat to steam ratio, operating pressures are achieved quickly with maximum efficiency. Electric boilers have no wasted fuel going out the stack as associated with fossil fuel, therefore, electric boilers are environmentally friendly. No NOx, (nitrogen oxides) are being transmitted to the atmosphere.
50 to 2000 kW elements mount verticallyCan be serviced and periodically maintained simply by unbolting the element(s) from the flanges in the top of the boiler’s “head”. Expansion and contraction of the top mounted elements cause scale to flake off and drop to the bottom of the boiler. Strategically located 3” x 4” handholes allow easy inspection and periodic clean-out maintenance.
Stainless steel heating elementsFulton uses low watt density elements* made of stainless steel. Stainless will not melt or anneal as easily as copper elements. The small 12 to 36 kW boilers use horizontally mounted elements at the bottom.
Fulton can custom build completely piped 1and wired skid mounted units.Save valuable time and expenses in the field by ordering complete skid mounted units ready for power and water hook up. Unit 1-50 kW (5 BHP) 600 PSIG steam boiler with dual level controls, skid-mounted, pre-piped with feed system and tandem feed-water preheaters. This unit is used for steam injection for pharmaceutical crystallization process.Unit 2-36 kW (3.6BHP) 15 PSIG electric steam boiler with 3 kW electric steam superheater skid mounted and pre-piped with return system and chemical feed system. Explosion proof, Class 1, Group C, D DN 1. All controls, instrumentation by Fulton including single source power connection. This unit is used for manufacturing/sterilization of surgical equipment.The element(s) are easily accessible-permit quick removal for service or inspection. Heating element thermostats are optional.
For over 60 years the Fulton vertical tubeless boilers have remained a compact trouble-free boiler supplying steam and hot water to virtually every type of industry imaginable.The Classic efficient FB-A, FB-B Fulton boilers are available in 13 sizes ranging from 4 to 150 BHP.Simplicity and reliability offer years of trouble-free operation. With no tubes or coils to scale up, rust or burn out, a Fulton Boiler reduces plant operating costs by eliminating down time and expensive repairs.All Fulton Boilers feature the Fulton designed top mounted down-fired standard power burner or new optional low emissions burner. The velocity of the premixed air and gas reduces the residence time in the low emissions burner. Due to this high velocity gas/air mixture, Fulton’s burners are capable of maintaining NOx concentrations below 20 PPM and 60 PPM CO corrected to 3% O2. The Fulton Low Emissions Burner is also under 20 ng NOx/joule output.
Fulton Engineers/Manufactures Total System for Industrial Process ApplicationsFulton, involved in engineering total systems to meet the needs of a specific application has been manufacturing steam boilers for over 60 years. Fulton’s engineering, drafting, and manufacturing capabilities can build just about anything around a customer’s needs. Fulton’s custom built, factory skid mounted and pre-piped equipment save a tremendous amount of time and work on the job site.
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